MICROGUARD 424 RATED CAPACITY INDICATOR SYSTEM OPERATION/TROUBLESHOOTING MANUAL TELESCOPIC BOOM CRANES HORIZONTAL DISPLAY 1918 EAST GLENWOOD PLACE, SANTA ANA CA 92705 Tel:(714) 259-9702 Fax:(714) 259-7626 MICROGUARD 424 OPERATION/TROUBLESHOOTING MANUAL PN W424103 REV A 02/13/01
The Greer Company is dedicated to the design and manufacture of electronic parts created to aid in crane operation and in the protection of crane operators and associated personnel. This manual has been developed to assist in helping Service Personnel to understand, locate, and identify problems that may arise during the operation of the MicroGuard 424 Rated Capacity Indicator System. Persons using this Manual must be familiar with the MicroGuard 424 System and with Electrical Servicing. Use of calibration routines without consultation with the Greer Company will invalidate the warranty. 1918 EAST GLENWOOD PLACE, SANTA ANA CA 92705 Tel:(714) 259-9702 Fax:(714) 259-7626 Page 2 of 52 W424103 REV A 02/13/01
MICROGUARD 424 RATED CAPACITY INDICATOR SYSTEM OPERATION/TROUBLESHOOTING MANUAL TABLE OF CONTENTS SECTION 1: OPERATION MICROGUARD 424 SYSTEM DESCRIPTION...4 DISPLAY WINDOWS...5-6 PUSH BUTTONS - ICONS - LAMPS - ALARMS...7-10 MICROGUARD 424 SYSTEM OPERATION...11 CONFIGURATION SELECTION...12-15 EXAMPLES OF CRANE SET UP...16-20 MAIN BOOM...16 MAIN BOOM PLUS 35' OFFSETTABLE FLY...17 MAIN BOOM PLUS 48' TELESCOPING FLY...18 ON TIRES...19 RIGGING/TRAVEL MODE...20 OPERATOR SETTABLE ALARMS...21-24 METHOD OF SETTING...22 EXAMPLES OF SETTING ALARMS...23-24 CANCELING ALARMS...24 PERIODIC INSPECTIONS...25-26 CHECKING THE ANTI TWO-BLOCK SYSTEM...25-26 ROUTINE MAINTENANCE...26 SECTION 2: TROUBLESHOOTING...27-51 1918 EAST GLENWOOD PLACE, SANTA ANA CA 92705 Tel:(714) 259-9702 Fax:(714) 259-7626 Page 3 of 52 W424103 REV A 02/13/01
MICROGUARD 424 SYSTEM DESCRIPTION This manual describes the function and operation of the MicroGuard 424 Rated Capacity Indicator (RCI) System for telescopic boom cranes. The MicroGuard 424 System is intended to aid the crane operator in efficient crane operation by continuously monitoring the load and warning of an approach to an overload or a two-block condition. This System, which monitors crane functions by means of high accuracy sensors, continuously compares the load suspended below the boom head with data from a copy of the crane capacity chart, stored in the computer memory. If an overload is approached, the MicroGuard 424 System warns the operator by means of audible and visual alarms and can be configured to cause function kick-out. MicroG uard 424 TEST W 100% MAX CRANE SET UP STO W ED DEDUCT DEDUCT WORKING AREA ERECTED STO W ED W INFORM ATION VIEW SET CLEAR DOW N UP OPERATOR ALARM S CONTRAST SELECT The MicroGuard 424 indicator provides the operator with a continuous display of: Rated Capacity Actual Load Percentage of Rated Capacity Radius of the Load Angle of the Main Boom Working Area Crane Configuration And by means of alternate display push buttons, it provides the operator with: Length of the Main Boom Height of the Boom Head On-screen messages provide the operator with visual indications of the various alarms, which may occur during normal operation of the MicroGuard 424 System. These values are displayed on the left and upper right display. The lower right display gives information about the currently selected crane configuration. 1918 EAST GLENWOOD PLACE, SANTA ANA CA 92705 Tel:(714) 259-9702 Fax:(714) 259-7626 Page 4 of 52 W424103 REV A 02/13/01
LEFT DISPLAY WINDOW DISPLAY WINDOWS 1 5 M icrog uard 424 TEST W MAX 5.82 3.46 W 100% 60% ATB ALARM INFORM ATION VIEW SET CLEAR DOW N UP OPERATOR ALARM S CONTRAST 2 3 4 1 MAXIMUM RATED CAPACITY is a digital display of the maximum permitted capacity. It is derived from the crane's capacity chart. A copy of this chart is stored in the computer memory and is the reference capacity for any lifting operation. Maximum Rated Capacity is dependent on the configuration currently selected. This configuration, shown in the lower right display, determines the section of the capacity chart to be used as the capacity reference. If maximum rated capacity is limited by parts of line, then the displayed MAXIMUM RATED CAPACITY is the rope capacity and the message, "ROPE LIMIT" is displayed in the information area. 2 The BAR GRAPH is an analog bar graph in the upper display that gives a visual indication of how much of the crane capacity is being used and the rate at which an overload is being approached. This bar graph in conjunction with the 100% capacity marker gives a visual indication of when the overload point is reached. 3 PERCENTAGE OF RATED CAPACITY is a part of the bar graph display. A digital readout within the bar graph display expresses Actual Load as a percentage of Maximum Rated Capacity. For percentages of less than 100%, the display will be at the right side of the bar graph. For percentages over 87%, the display will move to the center of the bar graph in order to make space for the leading edge of the bar graph. 4 The INFORMATION AREA provides the operator with a visual indication of the various alarms, which may occur during normal operation of the MicroGuard 424 System. For example, PRE-ALARM or OVERLOAD, ATB ALARM, and ROPE LIMIT. 5 ACTUAL LOAD is a digital display that shows total load suspended below the boom or jib head. It includes the load, slings, pins or tackle used to secure the load and the hook block. 1918 EAST GLENWOOD PLACE, SANTA ANA CA 92705 Tel:(714) 259-9702 Fax:(714) 259-7626 Page 5 of 52 W424103 REV A 02/13/01
DISPLAY WINDOWS RIGHT SIDE DISPLAYS 2 1 6 7 57.2 8 F 49.1 OUTRIGGERS CRANE SET UP STOWED DEDUCT DEDUCT ERECTED MAIN BOOM STOWED 360 WORKING AREA 3 4 5 1 The RADIUS/HEIGHT display gives a continuous indication of the radius of the load, which is the horizontal distance from the centerline of rotation to the centerline of the hook. When the Radius/Height push button is pressed, the display will give a momentary readout of the height of the boom head above ground level i.e., the vertical distance from the ground to the boom/jib head. Information about height is only displayed while the Radius/Height push button is pressed and held. 2 The PARTS OF LINE display shows the parts SELECT of line currently selected. If the parts of line selected has a lower safe working strength than the actual capacity, the MAXIMUM RATED CAPACITY display will show the reduced capacity and the message, "ROPE LIMIT" will appear in the information area. 3 The WINCH IN USE display indicates the selected winch. "F" indicates front; "R" indicates rear. 4 The ANGLE/LENGTH display gives a continuous indication of the angle of the main boom relative to horizontal. When the angle/length push button is pressed and held, the display will give a momentary readout of the length of the Main Boom from the boom foot pin to the shaft of the head machinery. Information about length is shown only while the Angle/Length push button is pressed and held. 5 The WORKING AREA is located in the lower right of the middle display. Descriptions conform to the current configuration selected and to the swing position of the crane upper. For example, the following messages will appear: Front, Side, Rear, 360 Line, Track (between tracks) 6 The OUTRIGGERS or TIRES display is locateded in the lower left of the middle display. Readout is determined by the current duty selection. 7 The LIFTING POINT is continuously shown in the lower display. If an attachment such as a fly is erected but is not the lifting point, the DEDUCT (see Push Buttons, Icons, and Lamps) light will be illuminated. 1918 EAST GLENWOOD PLACE, SANTA ANA CA 92705 Tel:(714) 259-9702 Fax:(714) 259-7626 Page 6 of 52 W424103 REV A 02/13/01
LEFT DISPLAY PUSH BUTTONS - ICONS - LAMPS - ALARMS 1 2 3 4 1 TEST is a push button used to initiate a system self-test; it is also used to display fault codes. 8 7 TEST W MAX W LEFT DISPLAY INFORMATION 100% 5 6 2 CANCEL ALARM is a push button used to silence the audible alarm when the alarm has occurred as a result of either an Overload, an Anti Two-Block alarm, or an Operator Settable alarm. CANCEL ALARM is also used to reset the function kick-out relay when it is necessary to by-pass function kick-out. VIEW SET CLEAR DOWN UP 9 10 11 12 13 3 The PRE-ALARM (AMBER) indicator illuminates at a pre-set value of 90% of Maximum Rated Capacity and provides a visual indication of an approach to an overload. 4 The OVERLOAD INDICATOR (RED) illuminates at a pre-set value of 100% of Maximum Rated Capacity and provides a visual indication of Maximum Allowed Load. The OVERLOAD INDICATOR will also illuminate whenever an anti two-block (A.T.B.) alarm occurs or a wire rope limit is exceeded or an operator SETTABLE alarm has been reached or exceeded. When the crane is equipped with function kick-out, this will occur simultaneously for an Overload, Wire Rope Limit, or an Anti Two-Block condition, but function kick-out will not occur when exceeding an operator set alarm. 5 The BAR GRAPH ICON is a part of the analog bar graph in the upper display. This display bar graph gives a visual indication of how much of the crane's capacity is being used and the rate at which an overload is being approached. The leading edge of the bar graph aligns with three colored bands in the bar graph indicator. Red indicates an overload. Between the red and amber is a black notch, which indicates 100% of rated capacity. The 100% RATED CAPACITY indicator is above the bar graph in the upper display and marks the point at which 100% of the rated capacity of the crane has been reached. When the value of 100% has been reached, it corresponds to the Maximum Rated Capacity in the upper display. 6 The INFORMATION AREA indicates the area of the upper display that provides the operator with a visual indication of the various alarms, which may occur during normal operation of the system. 7 The ACTUAL LOAD ICON indicates the area of the display that shows the total load suspended below the boom, fly, or jib head. It includes the load, any slings, pins or tackle used to secure the load and also includes the weight of the hook block. 8 The MAXIMUM RATED CAPACITY icon indicates the area of the upper display that gives a readout of maximum rated capacity for the currently selected configuration. 1918 EAST GLENWOOD PLACE, SANTA ANA CA 92705 Tel:(714) 259-9702 Fax:(714) 259-7626 Page 7 of 52 W424103 REV A 02/13/01
OPERATOR ALARM BUTTONS AND CONTRAST 9 VIEW is a push button used during the setting of operator alarms. It is used to start the routine and to view the current alarm settings. 10 SET is a push button used during the setting of operator alarms to set a new alarm setting. 11 CLEAR is a push button used during the setting of operator alarms to clear the current alarm setting. 12 CONTRAST (DOWN) is a push button used to decrease the display contrast. 13 CONTRAST (UP) is a push button used to increase the display contrast. 1918 EAST GLENWOOD PLACE, SANTA ANA CA 92705 Tel:(714) 259-9702 Fax:(714) 259-7626 Page 8 of 52 W424103 REV A 02/13/01
1 7 CRANE SET UP 2 3 UPPER RIGHT DISPLAY STOWED DEDUCT WORKING AREA UPPER RIGHT DISPLAY 1 The RADIUS/HEIGHT icon indicates the area of the display that gives a readout of radius and height. This icon is also a push button used to select the alternate display of height. HEIGHT is displayed only when the push button is pressed and held. When this push button is not pressed, the display readout is always the radius of the load. 6 2 The PARTS OF LINE icon indicates the area of the display that gives a read-out of the parts of line currently selected. This icon is also a push button used to select the parts of line in use on the selected winch. 3 The WINCH SELECT icon indicates the area of the display that gives a readout of the winch currently selected. This icon is also the push button used to select the Front or Rear winch. When switching between winches, the parts of line previously selected for the other winch is recorded and displayed whenever the alternate winch is selected. 4 The ANGLE/LENGTH icon indicates the area of the display that gives a read-out of angle or length. This icon is also a push button used to select the alternate display of Length. Length is displayed only when the push button is pressed and held. When this push button is not pressed, the display will always show the Angle of the main boom. 5 WORKING AREA indicates the part of the display where messages can be displayed. Messages in this area will conform to the current duty selection and the swing position of the crane upper. 6 STOWED DEDUCT is a push button that is used to start the selection of deducts for stowed attachments. The first press of the button will start the menu, after which it will function as a down-arrow for scrolling. 7 CRANE SET UP indicates the area of the display showing a read-out of the currently selected crane configuration (on OUTRIGGERS or TIRES). CRANE SETUP is also a push button used to start the selection of configurations. 4 5 1918 EAST GLENWOOD PLACE, SANTA ANA CA 92705 Tel:(714) 259-9702 Fax:(714) 259-7626 Page 9 of 52 W424103 REV A 02/13/01
LOWER RIGHT PUSH BUTTONS AND ICONS 1 2 DEDUCT 3 ERECTED STOWED 5 6 SELECT 4 1 and 3 UP/DOWN ARROWS are push buttons used as arrows for scrolling. 2 DEDUCT INDICATOR is an icon that contains two amber lamps, which indicate stowed and erected deducts. When a deduct is selected, the appropriate lamp will illuminate to warn the operator that a deduct has been applied. 4 and 6 RIGHT and LEFT ARROW are push buttons used in calibration routines. 5 SELECT is a push button used to terminate all selection and calibration routines. 1918 EAST GLENWOOD PLACE, SANTA ANA CA 92705 Tel:(714) 259-9702 Fax:(714) 259-7626 Page 10 of 52 W424103 REV A 02/13/01
MICROGUARD 424 SYSTEM OPERATION At start-up, the MicroGuard 424 System automatically performs a self-test. Upon completion of the self-test, the System goes directly to the normal working screen. The self-test can be initiated at any time during normal operation by pressing the TEST button. TEST One press (press and release) will cause the system to execute a self-test routine during which all lamps, audible alarms, and digital displays will be functionally tested, and all memory areas will be checked for accuracy. If faults in the system are detected during a test, the information area in the upper display will show the word FAULT. If the word FAULT occurs, press and hold the TEST button. This will cause the display to change to the FAULT mode. In this mode, information about the fault condition will be displayed in the middle display by means of an error code. CANCEL ALARM CANCEL ALARM is used to cancel the audible alarm when the alarm has occurred as a result of either an Overload, an Anti Two-Block alarm (A.T.B.) or an Operator Settable alarm. The audible alarm may be canceled by pressing and releasing the CANCEL ALARM button. The audible alarm remains canceled until the condition, which caused the alarm, has been removed. For example, if the audible alarm was canceled because of an overload condition, it will remain canceled until the overload condition is removed. However, if a different alarm (e.g., an anti two-block condition) was to occur when the audible alarm was still canceled for an earlier overload condition, the new alarm condition would cause the audible alarm to be restarted. CANCEL ALARM is also used to reset the function kick-out relay when it is necessary to by-pass a function kick-out that has occurred as a result of either an overload or an A.T.B. alarm. The relay is reset by first canceling the audible alarm [as described above] and then pressing and holding the CANCEL ALARM button for about 3 seconds, after which the function kick-out relay will be set to normal operation. However, should another different alarm condition occur when the relay had previously been overridden, then the newly occurring alarm condition would cause the motion cut to be restarted. CANCEL ALARM is a temporary function. The audible alarm or function kick-out is automatically reset when the condition that caused the alarm is no longer present. WARNING WHEN FUNCTION KICK-OUT IS RESET BY MEANS OF THE CANCEL ALARM BUTTON YOU ARE NO LONGER PROTECTED AGAINST THE CONDITION THAT CAUSED THE FUNCTION KICK-OUT. 1918 EAST GLENWOOD PLACE, SANTA ANA CA 92705 Tel:(714) 259-9702 Fax:(714) 259-7626 Page 11 of 52 W424103 REV A 02/13/01
CONFIGURATION SELECTION In the normal operational mode, the MicroGuard 424 System is programmed to retain the configuration last selected. Each time the system is powered up, it will automatically choose that configuration. Only when the crane is rigged differently must a new configuration be selected. CRANE SET UP The menu for the crane set up consists of up to 7 consecutive steps. Steps that are not available are automatically skipped by the program during the Crane Set Up procedure. 1. Select Outriggers, Tires, Rigging/Travel mode. 2. Select Counterweight configuration (If available). 3. Select Boom configuration or Telescope Mode (If available). 4. Select Auxiliary Head fitted or not fitted. 5. Select Lifting Attachments. 6. Select Lifting Point for Front Winch. 7. Select Lifting Point for Rear Winch. AFTER THE SELECTIONS MADE DURING CRANE SET UP, IT IS ONLY NECESSARY TO USE THE WINCH PUSH BUTTON TO SELECT THE LIFTING POINT. ALL OF THE INFORMATION REQUIRED BY THE SYSTEM IS ENTERED DURING CRANE SET-UP. THE PARTS OF LINE IN USE FOR EACH WINCH MUST ALSO BE SET FOR THE SYSTEM TO OPERATE CORRECTLY. FOR SPECIFIC EXAMPLES OF CRANE SET-UP, REFER TO PAGES 16-20. PARTS-OF OF-LINE Press and hold the PARTS-OF-LINE push button to scroll through the available parts of line. The new value is automatically registered when the button is released. The number chosen applies only to the winch currently selected and a value must be programmed for both winches. WINCH The current selection is shown in the display by use of the letter F for front winch and the letter R for rear winch. To change the selection, press the WINCH select push button. Successive pressing of the button will change the selection from one to the other. After the initial setup, the system retains the Parts-of-Line and Lifting Point and Deducts for each winch. RIGGING TRAVEL MODE The Rigging /Travel mode is selected as part of the carrier options. This mode is used to facilitate the rigging and travel of the crane by inhibiting motion-cut and audible alarm while selected. The information screen is restricted to the display of radius, length, angle, height and precautionary messages during the time that the mode is selected. To return to normal operation, press CRANE SET UP. 1918 EAST GLENWOOD PLACE, SANTA ANA CA 92705 Tel:(714) 259-9702 Fax:(714) 259-7626 Page 12 of 52 W424103 REV A 02/13/01
STOWED DEDUCTS When attachments such as flys are stowed, it is necessary to make a reduction in the rated capacity of the crane. This reduction, also called a deduct, is specified in the capacity chart. The MG424 has the ability to store this data and to make the deduct from the chart. This reduction is applied by use of the DEDUCT controls as follows. Start the selection by pressing the STOWED push button. The display will change to show the current selection in the center display. Use the UP or DOWN arrow to scroll through the selection menu. When at the required Deduct, press the SELECT push button to complete the selection of the new Deduct and return to the normal working screen. In order to remind the operator that a DEDUCT is applied, a lamp is illuminated in the deduct information panel, which is below the Stowed push button. To view the current selection, when indicated by the illuminated lamp, press the Stowed push button. After confirming or changing the selection, press the SELECT push button to complete the selection and return to the normal working screen. ALTERNATE DISPLAYS The primary position displays are those of RADIUS and ANGLE. There are alternate displays of HEIGHT and LENGTH available for display but these are only displayed during the time that the alternate display push buttons are pressed. Height alternates with Radius, and Length alternates with Angle. HEIGHT DISPLAY Height Display is a push button, used to select the alternate display of Height. Height is displayed only when the push button is pressed and held. When the push button is not pressed, the display always indicates Radius. LENGTH DISPLAY Length Display is a push button used to select the alternate display of Length. Length is displayed only when the push button is pressed and held. When this push button is not pressed, the display always indicates the Angle of the main boom. 1918 EAST GLENWOOD PLACE, SANTA ANA CA 92705 Tel:(714) 259-9702 Fax:(714) 259-7626 Page 13 of 52 W424103 REV A 02/13/01
CONFIGURATION SELECTION (Link-Belt Model 70 shown) START THE SELECTION OF CRANE CONFIGURATION BY PRESSING "CRANE SET UP" CRANE SET UP SCROLL TO CARRIER OR SELECT OUTRIGGERS FULLY EXT. ON TIRES STATIONARY PICK AND CARRY RIGGING TRAVEL SCROLL TO COUNTERWEIGH T OR SELECT COUNTERWEIGH T ATTACHED COUNTERWEIGH T REMOVED SCROLL TO BOOM OR MAIN BOOM MAIN BOOM + MANUAL SELECT SCROLL TO AUX. HEAD OR SELECT AUX. HEAD FITTED AUX. HEAD NOT FITTED SCROLL TO ATTACHMENT OR SELECT NO ATTACHMENT +35' OFSET FLY 2 +48' TELE FLY 2 +45' TUBE JIB 5 +60' TUBE JIB 30 +35' OFSET FLY 15 +48' TELE FLY 15 +45' TUBE JIB 17.5 +60' TUBE JIB 45 +35' OFSET FLY 30 +48' TELE FLY 30 +45' TUBE JIB 30 +75' TUBE JIB 5 +35' TELE FLY 2 +61' TELE FLY 2 +45' TUBE JIB 45 +75' TUBE JIB 17.5 +35' TELE FLY 15 +61' TELE FLY 15 +60' TUBE JIB 5 +75' TUBE JIB 30 +35' TELE FLY 30 +61' TELE FLY 30 +60' TUBE JIB 17.5 +75' TUBE JIB 45 SCROLL TO FRONT WINCH LIFTING POINT OR SELECT NO ATTACHMENT +35' OFSET FLY 2 +48' TELE FLY 2 +45' TUBE JIB 5 +60' TUBE JIB 30 +35' OFSET FLY 15 +48' TELE FLY 15 +45' TUBE JIB 17.5 +60' TUBE JIB 45 +35' OFSET FLY 30 +48' TELE FLY 30 +45' TUBE JIB 30 +75' TUBE JIB 5 +35' TELE FLY 2 +61' TELE FLY 2 +45' TUBE JIB 45 +75' TUBE JIB 17.5 +35' TELE FLY 15 +61' TELE FLY 15 +60' TUBE JIB 5 +75' TUBE JIB 30 +35' TELE FLY 30 +61' TELE FLY 30 +60' TUBE JIB 17.5 +75' TUBE JIB 45 (CONTINUED ON NEXT PAGE) 1918 EAST GLENWOOD PLACE, SANTA ANA CA 92705 Tel:(714) 259-9702 Fax:(714) 259-7626 Page 14 of 52 W424103 REV A 02/13/01
SCROLL TO REAR WINCH LIFTING POINT OR SELECT NO ATTACHMENT +35' OFSET FLY 2 +48' TELE FLY 2 +45' TUBE JIB 5 +60' TUBE JIB 30 +35' OFSET FLY 15 +48' TELE FLY 15 +45' TUBE JIB 17.5 +60' TUBE JIB 45 +35' OFSET FLY 30 +48' TELE FLY 30 +45' TUBE JIB 30 +75' TUBE JIB 5 +35' TELE FLY 2 +61' TELE FLY 2 +45' TUBE JIB 45 +75' TUBE JIB 17.5 +35' TELE FLY 15 +61' TELE FLY 15 +60' TUBE JIB 5 +75' TUBE JIB 30 +35' TELE FLY 30 +61' TELE FLY 30 +60' TUBE JIB 17.5 +75' TUBE JIB 45 FOLLOWING THE SELECTION OF CRANE SET UP, USE THE WINCH PUSH BUTTON TO SELECT THE LIFTING POINT. SET THE PARTS OF LINE IN USE FOR EACH WINCH USING THE PARTS OF LINE PUSH BUTTON. 1918 EAST GLENWOOD PLACE, SANTA ANA CA 92705 Tel:(714) 259-9702 Fax:(714) 259-7626 Page 15 of 52 W424103 REV A 02/13/01
MAIN BOOM FULLY EXTENDED OUTRIGGERS CRANE SET-UP EXAMPLES COUNTERWEIGHT ATTACHED PICKING FROM THE MAIN BOOM WITH THE FRONT WINCH, 6 PARTS OF LINE PICKING FROM THE AUXILIARY HEAD WITH THE REAR WINCH, 1 PART OF LINE THE 35-61' TELE FLY IS STOWED ON THE BOOM MicroG uard 424 START THE SELECTION BY PRESSING THE CRANE SET UP BUTTON (ITEM 1) TEST W MAX 100% 1 3 4 2 SELECT "FULLY EXTENDED OUTRIGGERS" CRANE SET UP STO W ED DEDUCT WORKING AREA SELECT "COUNTERWEIGHT ATTACHED" DEDUCT W INFORM ATION ERECTED STO W ED SELECT "MAIN BOOM" VIEW SET CLEAR DOW N UP SELECT "AUX. HEAD" FITTED OPERATOR ALARM S CONTRAST SELECT SELECT "NO ATTACHMENT" WINCH, "MAIN BOOM" SELECT LIFTING POINT FOR FRONT SELECT LIFTING POINT FOR REAR WINCH, "AUXILIARY HEAD" PRESS WINCH SELECT (ITEM 2) TO SELECT FRONT WINCH "F" PRESS PARTS OF LINE (ITEM 3) TO SELECT 6 PARTS OF LINE PRESS WINCH SELECT (ITEM 2) TO SELECT REAR WINCH "R" PRESS PARTS OF LINE (ITEM 3) TO SELECT 1 PART OF LINE PRESS STOWED DEDUCT (ITEM 4) TO SELECT 35-61' TELE FLY THE SYSTEM IS NOW SET UP, AS DESCRIBED ABOVE, AND THE ONLY SELECTION TO BE MADE IS FRONT OR REAR WINCH FOR THE LIFTING POINT. THE LOAD AND RADIUS WILL BE FOR THE SELECTED LIFTING POINT. 1918 EAST GLENWOOD PLACE, SANTA ANA CA 92705 Tel:(714) 259-9702 Fax:(714) 259-7626 Page 16 of 52 W424103 REV A 02/13/01
MAIN BOOM PLUS 35' OFFSETTABLE FLY FULLY EXTENDED OUTRIGGERS CRANE SET-UP EXAMPLES COUNTERWEIGHT REMOVED MAIN BOOM + MANUAL, THE AUXILIARY HEAD IS FITTED BUT IS NOT BEING USED PICKING FROM THE MAIN BOOM + MANUAL WITH THE FRONT WINCH, 6 PARTS OF LINE PICKING FROM THE 35' OFFSETTABLE FLY AT 15 OFFSET WITH THE REAR WINCH, 1 PART OF LINE NO STOWED ATTACHMENTS ON THE BOOM MicroG uard 424 START THE SELECTION BY PRESSING THE CRANE SET UP BUTTON (ITEM 1) TEST 3 2 SELECT "FULLY EXTENDED OUTRIGGERS" W MAX 100% 1 CRANE SET UP 4 STO W ED DEDUCT DEDUCT WORKING AREA SELECT "COUNTERWEIGHT REMOVED" SELECT "MAIN BOOM + MANUAL" ERECTED STO W ED W INFORM ATION SELECT "AUX. HEAD" FITTED VIEW SET CLEAR DOW N UP OPERATOR ALARM S CONTRAST SELECT SELECT "35' OFSET FLY, 15 OFFSET" SELECT LIFTING POINT FOR FRONT WINCH, "MAIN BOOM + MANUAL" SELECT LIFTING POINT FOR REAR WINCH, "35' OFSET FLY, 15 OFFSET" PRESS WINCH SELECT (ITEM 2) TO SELECT FRONT WINCH "F" PRESS PARTS OF LINE (ITEM 3) TO SELECT 6 PARTS OF LINE PRESS WINCH SELECT (ITEM 2) TO SELECT REAR WINCH "R" PRESS PARTS OF LINE (ITEM 3) TO SELECT 1 PART OF LINE THE SYSTEM IS NOW SET UP, AS DESCRIBED ABOVE, AND THE ONLY SELECTION TO BE MADE IS FRONT OR REAR WINCH FOR THE LIFTING POINT. THE LOAD AND RADIUS WILL BE FOR THE SELECTED LIFTING POINT. 1918 EAST GLENWOOD PLACE, SANTA ANA CA 92705 Tel:(714) 259-9702 Fax:(714) 259-7626 Page 17 of 52 W424103 REV A 02/13/01
MAIN BOOM PLUS 48' TELESCOPING FLY FULLY EXTENDED OUTRIGGERS CRANE SET-UP EXAMPLES COUNTERWEIGHT ATTACHED MAIN BOOM, THE AUX. HEAD IS NOT FITTED PICKING FROM THE MAIN BOOM WITH THE FRONT WINCH, 4 PARTS OF LINE PICKING FROM THE 48' TELESCOPING FLY AT 30 WITH THE REAR WINCH, 1 PART OF LINE NO STOWED ATTACHMENTS ON THE BOOM MicroG uard 424 START THE SELECTION BY PRESSING THE CRANE SET UP BUTTON (ITEM 1) TEST 3 2 SELECT "FULLY EXTENDED OUTRIGGERS" W MAX 100% 1 CRANE SET UP 4 STO W ED DEDUCT DEDUCT WORKING AREA SELECT "COUNTERWEIGHT ATTACHED" SELECT "MAIN BOOM" ERECTED STO W ED W INFORM ATION VIEW SET CLEAR DOW N UP SELECT "AUX. HEAD" NOT-FITTED OPERATOR ALARM S CONTRAST SELECT SELECT "48' TELE FLY, 30 OFFSET SELECT LIFTING POINT FOR FRONT WINCH, "MAIN BOOM" SELECT LIFTING POINT FOR REAR WINCH, "48' TELE FLY, 30 OFFSET" PRESS WINCH SELECT (ITEM 2) TO SELECT FRONT WINCH "F" PRESS PARTS OF LINE (ITEM 3) TO SELECT 4 PARTS OF LINE PRESS WINCH SELECT (ITEM 2) TO SELECT REAR WINCH "R" PRESS PARTS OF LINE (ITEM 3) TO SELECT 1 PART OF LINE THE SYSTEM IS NOW SET UP, AS DESCRIBED ABOVE, AND THE ONLY SELECTION TO BE MADE IS FRONT OR REAR WINCH FOR THE LIFTING POINT. THE LOAD AND RADIUS WILL BE FOR THE SELECTED LIFTING POINT. 1918 EAST GLENWOOD PLACE, SANTA ANA CA 92705 Tel:(714) 259-9702 Fax:(714) 259-7626 Page 18 of 52 W424103 REV A 02/13/01
ON TIRES PICK AND CARRY CENTERED OVER REAR CRANE SET-UP EXAMPLES COUNTERWEIGHT REMOVED MAIN BOOM PICKING FROM THE MAIN BOOM WITH THE FRONT WINCH, 4 PARTS OF LINE THE AUXILIARY HEAD IS FITTED BUT IS NOT USED ON TIRES (LBCE NOTE 22) THE 35-61' TELE FLY IS STOWED ON THE BOOM MicroGuard 424 START THE SELECTION BY PRESSING THE CRANE SET UP BUTTON (ITEM 1) TEST W MAX 100% 1 CRANE SET UP 3 4 STO W ED DEDUCT DEDUCT 2 WORKING AREA SELECT "PICK AND CARRY, CENTERED REAR" SELECT "COUNTERWEIGHT REMOVED" ERECTED STO W ED W INFORM ATION SELECT "MAIN BOOM" VIEW SET CLEAR DOW N UP OPERATOR ALARM S CONTRAST SELECT SELECT "AUX. HEAD" FITTED SELECT "NO ATTACHMENT" SELECT LIFTING POINT FOR FRONT WINCH, "MAIN BOOM" SELECT LIFTING POINT FOR REAR WINCH, "AUXILIARY HEAD" PRESS WINCH SELECT (ITEM 2) TO SELECT FRONT WINCH "F" PRESS PARTS OF LINE (ITEM 3) TO SELECT 4 PARTS OF LINE PRESS WINCH SELECT (ITEM 2) TO SELECT REAR WINCH "R" PRESS PARTS OF LINE (ITEM 3) TO SELECT 1 PART OF LINE PRESS STOWED DEDUCT (ITEM 4) TO SELECT 35-61' TELE FLY THE SYSTEM IS NOW SET UP, AS DESCRIBED ABOVE, AND THE ONLY SELECTION TO BE MADE IS FRONT WINCH FOR THE LIFTING POINT. THE LOAD AND RADIUS WILL BE FOR THE SELECTED LIFTING POINT. 1918 EAST GLENWOOD PLACE, SANTA ANA CA 92705 Tel:(714) 259-9702 Fax:(714) 259-7626 Page 19 of 52 W424103 REV A 02/13/01
RIGGING/TRAVEL MODE CRANE SET-UP EXAMPLES The Rigging /Travel mode is selected as part of the carrier options. This mode is used to facilitate the rigging and travel of the crane by inhibiting motion-cut and audible alarm while selected. The information screen is restricted to the display of radius, length, angle, height and precautionary messages during the time that the mode is selected. MicroGuard 424 START THE SELECTION BY PRESSING THE CRANE SET UP BUTTON (ITEM 1) TEST W MAX 100% 1 CRANE SET UP 3 4 STO W ED DEDUCT 2 WORKING AREA SELECT "RIGGING/TRAVEL MODE" THE LOWER RIGHT DISPLAY WILL READ: DEDUCT W INFORM ATION ERECTED STO W ED Rigging/Travel Mode VIEW SET CLEAR DOW N UP OPERATOR ALARM S CONTRAST SELECT THE LEFT DISPLAY WILL READ: To Resume, press CRANE SETUP CAUTION! THE RIGGING TRAVEL MODE INHIBITS ALL MOTION CUT AND AUDIBLE ALARMS FOR ALL ALARM CONDITIONS. IT IS TO BE USED ONLY FOR THE RIGGING OR TRAVEL OF THE MACHINE DURING WHICH TIME ALARMS AND MOTION CUT ARE NOT REQUIRED. BEFORE RESUMING ANY LIFTING OPERATIONS SELECT THE APPROPRIATE CONFIGURATION BY PRESSING CRANE SETUP. THE SYSTEM IS NOW SET UP, AS DESCRIBED ABOVE. RADIUS, ANGLE, AND ALTERNATES LENGTH AND HEIGHT WILL DISPLAYED IN THE RIGGING /TRAVEL MODE BUT LOAD INFORMATION IS NOT DISPLAYED. 1918 EAST GLENWOOD PLACE, SANTA ANA CA 92705 Tel:(714) 259-9702 Fax:(714) 259-7626 Page 20 of 52 W424103 REV A 02/13/01
OPERATOR SETTABLE ALARMS An additional feature of the MicroGuard 424 System is the provision of Operator Settable Alarms. These alarms, when properly set by the operator, provide a method of obstacle avoidance. This is achieved by means of minimum and maximum angle, maximum length and maximum height alarms. These alarms can be programmed for each job site and set rapidly for the prevailing site conditions, thereby aiding the operator in the safe operation of the crane. Most alarms will occur automatically as a result of limitations imposed by the capacity chart. The operator has control over additional alarms, which are set to define the working range of the machine for particular site requirements, and which will provide a measure of obstacle avoidance. Four alarms are available for operator use. MINIMUM ANGLE MicroG uard424 MAXIMUM ANGLE TEST W MAX MIN ANGLE 100% 31.5 MAX LENG TH MAX HEIGHT CRANE SET-UP STOW ED DEDUCT 92.0 98.5 W ORKING AREA MAXIMUM LENGTH MAXIMUM HEIGHT MAX ANGLE 75.4 DEDUCT ERECTEDSTOW ED W INFORM ATION VIEW SET CLEA R DOW N UP OPERATOR ALARM S CONTRAST SELECT 1918 EAST GLENWOOD PLACE, SANTA ANA CA 92705 Tel:(714) 259-9702 Fax:(714) 259-7626 Page 21 of 52 W424103 REV A 02/13/01
METHOD OF SETTING WARNING THE FOLLOWING EXAMPLES ARE GIVEN TO ILLUSTRATE METHODS OF SETTING ALARMS. THE ACTUAL VALUES GIVEN SHOULD NOT BE USED WITHOUT FIRST CHECKING THE CAPACITY CHART TO ENSURE SAFE, STABLE OPERATION UNDER THE CONDITIONS DESCRIBED. NOTE OPERATOR ALARMS WILL BE STORED IN THE COMPUTER MEMORY, EVEN IF THE CRANE IS SHUTDOWN. THE FOLLOWING PROCEDURES WILL DESCRIBE THE METHOD OF SETTING OR CANCELING ALARMS. LEFT DISPLAY Alarms can only be SET or CLEARED from within the alarm screen. From the main working screen, press VIEW to access the Operator Alarm screen. The cursor is an arrow that points to the INFORMATION alarm, which may be set or cleared and is always at the first W VIEW SET CLEAR DOWN UP position when entering the alarm screen. It may be moved to any position on the alarm screen by use of the UP/DOWN arrows. When the cursor is pointing to an alarm, the numerical value displayed will be the current position of the crane except when that alarm has previously been SET. In this case, the SET value will be indicated and will alternate with the word, "SET." Alarms which are set but to which the cursor is not pointing indicate the previously set value. Other alarms, which are NOT SET, are indicated by the word, "OFF." The functions of the push buttons when in the alarm screen are: VIEW Used to access the alarm screen in order to view the currently set alarms. SET Used to SET the alarm value. The alarm value is determined by the position of the crane at the time the SET button is pressed. CLEAR Used to clear a previously SET alarm. Alarms can only be CLEARED when the cursor is pointing to the item to be cleared. Use the UP/DOWN arrows to move the cursor to the desired alarm. Press CLEAR to cancel that alarm. UP/DOWN ARROWS Used to move the cursor up or down the screen to the alarm that is to be viewed, SET or CLEARED. SELECT Used to return to the normal operating screen. 1918 EAST GLENWOOD PLACE, SANTA ANA CA 92705 Tel:(714) 259-9702 Fax:(714) 259-7626 Page 22 of 52 W424103 REV A 02/13/01
EXAMPLES OF SETTING THE ALARMS Setting the alarm point is achieved by positioning the crane at the point at which the alarm is to sound and then, when in the operator alarm screen, using the SET push button to set the alarm. The following examples illustrate the use of the procedures. EXAMPLE A To have an alarm whenever the boom is below a 30 angle, use the following procedure: 1. Press VIEW to access the alarm screen. The cursor will be at MIN. ANGLE. 2. Move the boom to 30 angle. 3. Press SET to enter the alarm. The displayed value will be the alarm setting, and it will alternate with the word SET. 4. When the alarm is set, press SELECT to return to the working screen. The red lamp and the audible alarm will operate whenever the boom is below 30. The message MIN. ANGLE will appear in the INFORMATION area on the left display. EXAMPLE B To have an alarm whenever the boom is above 60 angle, use the following procedure: 1. Press VIEW to access the alarm screen. The cursor will be at MIN. ANGLE. Press the DOWN ARROW to move the cursor to MAX. ANGLE. 2. Move the boom to 60 angle. 3. Press SET to enter the alarm. The displayed value will be the alarm setting and it will alternate with the word SET. Press SELECT to return to the working screen. The red lamp and the audible alarm will operate whenever the boom is above 30. The message MIN. ANGLE will appear in the INFORMATION area on the left display. EXAMPLE C To have an alarm whenever the boom length exceeds 50 feet, use the following procedure: 1. Press VIEW to access the alarm screen. The cursor will be at MIN. ANGLE. Press the DOWN ARROW to move the cursor to MAX. LENGTH. 2. Extend the boom to 50 feet. 3. Press SET to enter the alarm. The displayed value will be the alarm setting and it will alternate with the word SET. Press SELECT to return to the working screen. The red lamp and the audible alarm will operate whenever the boom is extended beyond 50 feet. The message, MAX. LENGTH will appear in the INFORMATION area on the left display. 1918 EAST GLENWOOD PLACE, SANTA ANA CA 92705 Tel:(714) 259-9702 Fax:(714) 259-7626 Page 23 of 52 W424103 REV A 02/13/01
EXAMPLE D To have an alarm whenever the boom tip height exceeds 75 feet, use the following procedure: 1. Extend the boom and/or adjust the boom angle so that the tip height is 75 feet. 2. Press VIEW to access the alarm screen. The cursor will be at MIN. ANGLE. Press the DOWN ARROW to move the cursor to MAX. HEIGHT. 3. Press SET to enter the alarm. The displayed value will be the alarm setting and it will alternate with the word SET. Press SELECT to return to the working screen. The red lamp and the audible alarm will operate whenever the boom tip height exceeds 75 feet. The message MAX. HEIGHT will appear in the INFORMATION area on the left display. CANCELING ALARMS CLEAR is used to cancel a previously SET alarm. Alarms can only be CLEARED when the cursor is pointing to the item to be cleared. Canceling of alarms can be carried out regardless of the position of the crane. 1. Press VIEW to access the alarm screen. 2. Move the cursor to point to the alarm to be canceled. 3. Press CLEAR to cancel the alarm. The displayed value will be the current position of the crane and the word SET will no longer be displayed. 4. Move the cursor to point to the next alarm to be canceled. 5. When all the chosen alarms are canceled, press SELECT to return to the working screen. 1918 EAST GLENWOOD PLACE, SANTA ANA CA 92705 Tel:(714) 259-9702 Fax:(714) 259-7626 Page 24 of 52 W424103 REV A 02/13/01
PERIODIC INSPECTIONS CHECKING THE ANTI TWO BLOCK SYSTEM MAIN SWITCH 1. Lower the boom so that the A.T.B. switches can be reached by hand. 2. Set the Selector Switch located on the Main Switch housing to the "Main" position and check that raising the weight to trip the switch causes the A.T.B. alarm to operate. JIB SWITCHES If the crane is equipped with additional Jib switches, check as follows. 1. Connect the cable from the Jib switch to the receptacle on the Main Switch. 2. Set the Selector Switch to "Both". 3. Check that raising the weight and tripping the switch on EITHER the Main OR the Jib switch causes the A.T.B. alarm to operate. 4. Set the Selector Switch to "Jib". 5. Check that raising the weight on the Jib switch only and tripping the switch causes the A.T.B. alarm to operate. FUNCTION KICK-OUT If the crane is equipped with Function Kick-Out, check the operation of the system as follows: 1. With the crane in any normal working configuration, raise the hook block sufficiently to cause the A.T.B. switch to operate. 2. Check that when the audible alarm sounds the following functions are stopped: Main Winch Up Aux. Winch Up Boom Hoist Lower Telescope Out (all cylinders) 3. Check that when the CANCEL ALARM by-pass system is enabled or the RIGGING/TRAVEL MODE is selected, the audible alarm is silenced and the motions are restored. CAUTION WHEN CARRYING OUT THIS TEST THE FUNCTION KICK-OUT CIRCUITS DO NOT PROTECT THE CRANE. TAKE CARE THAT THE CRANE IS NOT PUT INTO AN ACTUAL TWO-BLOCK CONDITION INADVERTENTLY. DO NOT OPERATE THE CRANE UNDER THE ABOVE CONDITIONS. 1918 EAST GLENWOOD PLACE, SANTA ANA CA 92705 Tel:(714) 259-9702 Fax:(714) 259-7626 Page 25 of 52 W424103 REV A 02/13/01
SYSTEM CHECKS Check that the displayed boom angle agrees with the measured angle. Check that the displayed radius agrees with the measured operating radius. Check that the displayed boom length agrees with the actual boom length. If a known test weight is available, check that the displayed weight agrees with the test load. The displayed load includes the hook block and any lifting attachments such as slings, pins and shackles. If the capacity chart is rated for specific areas e.g., side, front or rear, the system should be checked by swinging the boom into the permitted areas and checking that the Rated Capacity reading agrees with the crane Capacity Chart. ROUTINE MAINTENANCE The MicroGuard 424 System has built-in self-test facilities and checks itself each time the system is switched on. Only a minimum level of preventive maintenance is required. This is restricted to visual inspections of cables and sensors for obvious signs of wear and tear and inspection of mechanical parts, such as extension reels and anti two-block switches. 1918 EAST GLENWOOD PLACE, SANTA ANA CA 92705 Tel:(714) 259-9702 Fax:(714) 259-7626 Page 26 of 52 W424103 REV A 02/13/01
MICROGUARD 424 OPERATION/TROUBLESHOOTING ESHOOTING MANUAL TABLE OF CONTENTS SECTION 2: TROUBLESHOOTING FAULT DIAGNOSTIC PROCEDURES...29 GROUP "A" FAULT CODES...30-31 POWER SUPPLY VOLTAGES...32 INPUT POWER...32 INTERNAL POWER SUPPLIES...32 ACCESSING THE COMPUTER AND TERMINATION BOARDS...33 CHECKING ANALOG DRIVE VOLTAGE...33 PRESSURE CHANNEL FAULT GUIDE...34-36 FUNCTIONAL TESTS...34 TRANSDUCER RESISTANCE MEASUREMENT...35 PISTON PRESSURE TRANSDUCER...35 ROD PRESSURE TRANSDUCER...35-36 ANALOG DRIVE VOLTAGE...36 BOOM EXTENSION SENSOR AIN2...37 BOOM ANGLE SENSOR AIN3...38 SWING POTENTIOMETER AIN5 AND AIN6...39 NO DUTY FOUND...40 OTHER SYSTEM FAULTS...40 EXECUTIVE ROM...40 PERSONALITY ROM...40 SCRATCHPAD RAM...40 DUTY ROM...40 CURRENT DUTY BAD...40 CONFIGURATION UNCALIBRATED...40 DIGITAL I/O AND ANALOG I/O...40 DISPLAY UNIT...40 ANTI TWO-BLOCK SYSTEM...41 ANTI TWO-BLOCK LOGIC LEVELS...42 1918 EAST GLENWOOD PLACE, SANTA ANA CA 92705 Tel: (714) 259 9702 Fax: (714) 259 7626 27 of 52 W424103 REV A 02/13/01
PARTS REPLACEMENT...43-45 PRESSURE TRANSDUCERS...43 EXTENSION REEL...43 BOOM ANGLE SENSOR HTC8660 ONLY...43 BOOM ANGLE SENSOR...44 EXECUTIVE ROM CHIP...44 PERSONALITY ROM CHIP...44 DUTY ROM CHIP...44 COMPUTER BOARD...44 COMPUTER BOX...45 CHIP REMOVAL AND INSTALLATION...45 GLOSSARY...46-48 COMPUTER BOARD LAYOUT...49 TERMINATION BOARD LAYOUT...50 EXTENSION REEL LAYOUT...51 1918 EAST GLENWOOD PLACE, SANTA ANA, CA 92705 Tel: (714) 259 9702 Fax: (714) 259 7626 28 of 52 W424103 REV A 02/13/01
TROUBLESHOOTING FAULT DIAGNOSTIC PROCEDURES Faults in the MicroGuard 424 System are detected automatically. Each time the MicroGuard 424 System is switched on it goes through a start up self-test which lasts about 2-3 seconds. During normal operation a selftest can be initiated by pressing the TEST button on the display. Fault conditions in external sensors are detected without the need for a system self-test. Faults detected in the MicroGuard 424 System during self-test are indicated on the display as follows: The word FAULT will appear in the information area of the left display. The RED LAMP will illuminate and the AUDIBLE ALARM will sound. When faults occur in the system they can be diagnosed using the display. Details of the fault locations are obtained by pressing and holding the test button. Holding the test button will cause the system to go through a self-test during which faults will be detected. Following completion of the self-test: If the test button continues to be pressed, the fault screen will appear. The fault screen will remain visible for as long as the test button is pressed. Information will be displayed on the screen in four groups. Group A Sensor faults Group B I/O faults Group C Memory faults Group D General faults FAULT CODES GROUP A ANALOG SENSORS CODE AAA 000 NO FAULTS 001 AIN0 PISTON PRESSURE TRANSDUCER 002 AIN1 ROD PRESSURE TRANSDUCER 004 AIN2 EXTENSION SENSOR 008 AIN3 BOOM ANGLE SENSOR 016 AIN4 S STRUCTURE ANGLE SENSOR 032 AIN5 SWING POTENTIOMETER A 064 AIN6 SWING POTENTIOMETER B GROUP B INPUTS AND OUTPUTS CODE BB FAULT 00 NO FAULTS 01 1 DIGITAL INPUT AND OUTPUT 02 2 ANALOG INPUT AND OUTPUT 04 4 DISPLAY UNIT GROUP C MEMORY CODE CC 00 NO FAULTS 01 1 EXECUTIVE ROM 02 2 DUTY ROM 04 4 SCRATCHPAD RAM 08 8 PERSONALITY ROM GROUP D GENERAL CODE DD 00 NO FAULTS 01 1 NO DUTY FOUND 02 2 CURRENT DUTY BAD 04 4 CONFIGURATION UNCALIBRATED 08 8 2 HZ OSCILLATOR 1918 EAST GLENWOOD PLACE, SANTA ANA, CA 92705 Tel: (714) 259 9702 Fax: (714) 259 7626 29 of 52 W424103 REV A 02/13/01
TEST MicroGuard 414 W MAX PRESS AND HOLD 100% AAA B CC DD 0 0 0 0 00 0 0 CRANE SET UP STOWED DEDUCT DEDUCT ERECTED STOWED WORKING AREA W INFORMATION FAULT CODES VIEW SET CLEAR DOWN UP OPERATOR ALARMS CONTRAST GROUP A FAULT CODES If a fault is detected by the system, a number will appear under one or more of the four group headings A through D. This number will correspond to one or more fault diagnostic numbers. The meaning of these numbers can be determined by looking at the appropriate code in the fault interpretation table. Group A fault codes relate to analog sensors. Each sensor is allocated a number and this number is also the number of the channel to which it is connected in the system. Sensor 0 Piston Pressure Sensor 1 Rod Pressure Sensor 2 Extension Sensor Sensor 3 Boom Angle Sensor 4 Superstructure Angle Sensor 5 Swing Potentiometer A Sensor 6 Swing Potentiometer B Each sensor is allocated a FAULT CODE and this is the number that appears under the group heading in the fault code display. 001 Sensor 0 Piston Pressure 002 Sensor 1 Rod Pressure 004 Sensor 2 Extension Sensor 008 Sensor 3 Boom Angle 016 Sensor 4 S structure Angle 032 Sensor 5 Swing Pot r A 064 Sensor 6 Swing Pot r B When there are no faults detected in the system, 000 will appear under all group headings indicating that there are no detected faults in the system. When there are faults in only one sensor, the code will be one of the codes listed above. When there are faults in more than one sensor, the codes indicated will be the sum of the fault codes. EXAMPLES OF FAULT CODES Fault 0 AAA B CC DD 000 0 00 00 No faults detected. Fault 1 AAA B CC DD 001 0 00 00 Piston pressure transducer. Fault 2 SELECT AAA B CC DD 002 0 00 00 Rod pressure transducer 1918 EAST GLENWOOD PLACE, SANTA ANA, CA 92705 Tel: (714) 259 9702 Fax: (714) 259 7626 30 of 52 W424103 REV A 02/13/01
Fault 3 AAA B CC DD 003 0 00 00 Piston pressure transducer Rod pressure transducer Fault 4 AAA B CC DD 004 0 00 00 Extension Sensor Fault 5 AAA B CC DD 005 0 00 00 Piston pressure transducer Extension sensor Fault 6 AAA B CC DD 006 0 00 00 Rod pressure transducer Extension sensor Rod pressure transducer Fault 7 AAA B CC DD 007 0 00 00 Piston pressure transducer Rod pressure transducer Extension sensor Fault 8 AAA B CC DD 008 0 00 00 Boom angle sensor Fault 9 AAA B CC DD 009 0 00 00 Piston pressure transducer Boom angle sensor Fault 10 AAA B CC DD 010 0 00 00 Boom angle sensor Rod pressure transducer Fault 11 AAA B CC DD 009 0 00 00 Boom angle sensor Piston pressure transducer Rod pressure transducer Fault 32 AAA B CC DD 032 0 00 00 Swing potentiometer A Fault 64 AAA B CC DD 064 0 00 00 Swing potentiometer B Fault 96 AAA B CC DD 096 0 00 00 Swing potentiometer A Swing potentiometer B This sequence continues up to the maximum fault code of 127 that is the sum of all group A fault codes. Fault 127 AAA B CC DD 127 0 00 00 All analog sensors. This fault condition is seldom caused by the simultaneous failure of all sensors. It is more usually the result of the failure of the analog drive voltage, which is the supply voltage for all sensors. This power supply fault may be due to the failure of the power supply or may be due to damage to the cable that connects the sensor to the computer. When this fault occurs, carry out Power Supply Voltage checks before checking individual sensors. 1918 EAST GLENWOOD PLACE, SANTA ANA, CA 92705 Tel: (714) 259 9702 Fax: (714) 259 7626 31 of 52 W424103 REV A 02/13/01
POWER SUPPLY VOLTAGES The Computer Unit contains 2 major boards, the Terminal Connection Board and the Computer Board. Both of these assemblies are located in an aluminum box that is usually located on the rear wall of the cab or can be inside or outside the cab depending on crane model. All of the cables from the various sensors and the display are connected to the Terminal Connection Board. To gain access to the Terminal Connection Board, refer to Page 33 of this manual. Battery + Battery - INPUT POWER The computer operates from an input voltage in the range 11 to 36 volts DC. This input voltage is measured across the B+ and B- terminals on the Terminal Connection Board and corresponds to the battery voltage of the crane. At voltages below 10.5 and above 38 volts the system will power down until correct voltage is restored. InternalPow er Term inals If the INPUT POWER is not within these limits, check the battery and/or alternator before servicing the computer. INTERNAL POWER SUPPLIES The computer generates its own internal power from the incoming battery voltage. This power can be monitored at the test points inside the computer adjacent to the fuses and Battery Input Terminals. To monitor the Internal Power Supplies, use a Digital Voltmeter set to the appropriate DC voltage range. Connect the black (-ve) lead to GND Connect the red (+ve) lead in turn to +15V +/- 0.1-15V +/- 0.1 +5V +/- 0.1 If the voltages are out of range, it may be necessary to replace the computer. Before replacing the computer, refer to Greer Company Product Support Department 714-259-9702 InternalPow er Term inals G round +5 volts + 15 volts -15 volts 1918 EAST GLENWOOD PLACE, SANTA ANA, CA 92705 Tel: (714) 259 9702 Fax: (714) 259 7626 32 of 52 W424103 REV A 02/13/01
ACCESSING MAIN COMPUTER BOARD AND TERMINATION BOARD 1. Remove the four screws (1) securing the computer lid to the computer box. This lid is NOT hinged. Take care not to allow the lid to fall from the box. Set the lid aside. 2. Under the lid you will see the Main Computer Board. This board contains the microprocessor and its related components. This unit is held in place by two screws (2) located at the left and right of the Main Computer Board backing plate and is connected to the Terminal Connection Board via 2 ribbon cables. These cables carry the signals to and from the Termination Board. These will be to the top of the Main Computer Board. 3. If you are going to check voltages on the Termination Board, remove the two screws located at the left and right of the Main Computer Backing Plate and swing the assembly up. Take care not to damage the ribbon cables. These ribbon cables must remain connected to the Main Computer Board for voltage checks. CHECKING ANALOG DRIVE VOLTAGE To check the Analog Sensor Drive Voltage, use the following procedure: 1. Access the Termination Board. 2. With the system power on and a digital volt meter set to read DC voltage, place the negative lead on any - DR (- Drive) terminal (1) of the Analog Input Group. 3. Place the positive lead of the meter on any +DR (+ Drive) terminal (2). each cable, one at a time, checking the Analog Drive Voltage after each cable is connected. 7. If after reconnecting any one of the sensors the Analog Drive Voltage goes out of range, it is probable that the wiring to the sensor is grounded or the sensor itself is faulty. Check all wires and the sensor itself and repair or replace as required. DRIVE VOLTAGE 5.25 + /-0.1 +DR AIN0 -DR +DR +DR AIN2 -DR AIN3 TX0+ AIN4 +DR -DR TX0- TX1+ TX1- AIN1 -DR +DR AIN5 AIN6 -DR +VP +VP +VP +VP The analog drive voltage can be m easured betw een any D R+ term inal and any D R- term inal. It is 5.25volts DC +/-0.1 volts. 4. The voltage should be 5.25+/-0.1volts. 5. If the Analog Drive Voltage is not within this range, disconnect all of the external sensor cables, including pressure transducers, cables 1 through 5. 6. Recheck the Analog Drive Voltage. If the voltage is still out of range, the Computer Board will need to be replaced. If the voltage is within range, reconnect 1918 EAST GLENWOOD PLACE, SANTA ANA, CA 92705 Tel: (714) 259 9702 Fax: (714) 259 7626 33 of 52 W424103 REV A 02/13/01